Interconnect Structures, Packaged Semiconductor Devices, and Methods of Packaging Semiconductor Devices

ABSTRACT

Interconnect structures, packaged semiconductor devices, and methods of packaging semiconductor devices are disclosed. In some embodiments, an interconnect structure includes dielectric layers, a conductive layer disposed in the dielectric layers, and a via layer disposed in the dielectric layers proximate the conductive layer. An underball metallization (UBM) layer is disposed in the dielectric layers proximate the via layer. A first connector coupling region is disposed in the via layer and the UBM layer. A via layer portion of the first connector coupling region is coupled to a first contact pad in the conductive layer. A second connector coupling region is disposed in the UBM layer. The second connector coupling region is coupled to a conductive segment in the UBM layer and the via layer. The second connector coupling region is coupled to a second contact pad in the conductive layer by the conductive segment.

PRIORITY CLAIM AND CROSS-REFERENCE

This application is a divisional of U.S. patent application Ser. No.16/577,645, filed on Sep. 20, 2019, entitled “Interconnect Structures,Packaged Semiconductor Devices, and Methods of Packaging SemiconductorDevices,” now U.S. Pat. No. 11,031,363 issued Jun. 8, 2021, whichapplication is a divisional of U.S. patent application Ser. No.14/632,858, filed on Feb. 26, 2015, entitled “Interconnect Structures,Packaged Semiconductor Devices, and Methods of Packaging SemiconductorDevices,” now U.S. Pat. No. 10,497,660 issued Dec. 3, 2019, whichapplications are hereby incorporated by reference herein as ifreproduced in their entirety.

BACKGROUND

Semiconductor devices are used in a variety of electronic applications,such as personal computers, cell phones, digital cameras, and otherelectronic equipment. Semiconductor devices are typically fabricated bysequentially depositing insulating or dielectric layers, conductivelayers, and semiconductive layers of material over a semiconductorsubstrate, and patterning the various material layers using lithographyto form circuit components and elements thereon. Dozens or hundreds ofintegrated circuits are typically manufactured on a single semiconductorwafer. The individual dies are singulated by sawing the integratedcircuits along scribe lines. The individual dies are then packagedseparately, in multi-chip modules, or in other types of packaging.

The semiconductor industry has experienced rapid growth due tocontinuous improvement in the integration density of a variety ofelectronic components (e.g., transistors, diodes, resistors, capacitors,etc.). For the most part, this improvement in integration density hascome from repeated reductions in minimum feature size (e.g., shrinkingthe semiconductor process node towards the sub-20 nm node), which allowsmore components to be integrated into a given area. As the demand forminiaturization, higher speed, and greater bandwidth, as well as lowerpower consumption and latency has grown recently, there has grown a needfor smaller and more creative packaging techniques for semiconductordies.

As semiconductor technologies further advance, stacked semiconductordevices, e.g., three dimensional integrated circuits (3DICs), haveemerged as an effective alternative to further reduce the physical sizeof semiconductor devices. In a stacked semiconductor device, activecircuits such as logic, memory, processor circuits, and the like arefabricated on different semiconductor wafers. Two or more semiconductorwafers may be installed or stacked on top of one another to furtherreduce the form factor of the semiconductor device. Package-on-package(POP) devices are one type of 3DIC wherein dies are packaged and arethen packaged together with another packaged die or dies.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1A is a cross-sectional view that illustrates a first connectorcoupling region of an interconnect structure in accordance with someembodiments of the present disclosure.

FIG. 1B is a top view of the first connector coupling region shown inFIG. 1A.

FIG. 2A is a cross-sectional view that illustrates a second connectorcoupling region of an interconnect structure in accordance with someembodiments.

FIG. 2B is a top view of the second connector coupling region shown inFIG. 2A.

FIG. 3 is a bottom view that shows a plurality of connectors of aninterconnect structure in accordance with some embodiments.

FIG. 4 is a cross-sectional view that illustrates a package-on-package(POP) device in accordance with some embodiments that includes theplurality of connectors coupled to a plurality of first connectorcoupling regions and a plurality of second connector coupling regions.

FIGS. 5, 6, and 7 are bottom views that show a plurality of connectorsof an interconnect structure in accordance with some embodiments.

FIG. 8 is a cross-sectional view that illustrates a POP device inaccordance with some embodiments.

FIG. 9 is a bottom view that shows a plurality of connectors of aninterconnect structure in accordance with some embodiments.

FIG. 10 is a cross-sectional view of a portion of a packagedsemiconductor device that illustrates some additional material layersand features of an interconnect structure in accordance with someembodiments.

FIG. 11 is a flow chart illustrating a method of packaging asemiconductor device in accordance with some embodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Interconnect structures, packaged semiconductor devices, and methods ofpackaging semiconductor devices are disclosed in the present disclosure.The interconnect structures include ground-up connector coupling regionsin areas with high reliability and stress risks, and non-ground-upconnector coupling regions in other areas. The interconnect structuresare utilized in packages and packaged semiconductor devices. In someembodiments, POP devices are formed, wherein two packaged semiconductordevices are coupled together. One of the packaged semiconductor devicesincludes the interconnect structure described herein. One of thesemiconductor devices comprises a fan-out structure and the othersemiconductor device comprises a packaged dynamic random access memory(DRAM) device in some embodiments, to be described further herein.

FIG. 1A is a cross-sectional view that illustrates a first connectorcoupling region 100 of an interconnect structure 122 a in accordancewith some embodiments of the present disclosure. The interconnectstructure 122 a comprises a plurality of dielectric layers 101 a and 101b. The dielectric layers 101 a and 101 b may each comprise a pluralityof insulating material layers. The dielectric layers 101 a and 101 b maycomprise a material such as silicon nitride (SiN), silicon dioxide(SiO₂), silicon oxynitride (SiON), low dielectric constant (k) materialshaving a k value less than a k value of silicon dioxide, which is about3.9, passivation materials such as polyimide (PI), benzocyclobutene(BCB), polybenzoxazole (PBO), or epoxy, other insulating materials, orcombinations or multiple layers thereof, as examples. In someembodiments, dielectric layer 101 a comprises a plurality of insulatingmaterial layers, and dielectric layer 101 b comprises a singleinsulating material layer that is formed after a connector 114 iscoupled to the interconnect structure 122 a.

A conductive layer 102 is disposed within dielectric layer 101 a. Theconductive layer 102 comprises a plurality of contact pads 104 formedusing a patterning and deposition process over one of the plurality ofinsulating material layers of the dielectric layer 101 a. The conductivelayer 102 may also include conductive lines or traces 105 coupled to thecontact pads 104 or adjacent the contact pads 104, for example. Thecontact pads 104 may comprise aluminum (Al), copper (Cu), tin (Sn),nickel (Ni), gold (Au), silver (Ag), other electrically conductivematerials, or multiple layers or combinations thereof, as examples. Thecontact pads 104 may be formed using an electrolytic plating orelectro-less plating process, for example. The size, shape, and locationof the contact pads 104 in the figures are only for illustrationpurposes. A plurality of the contact pads 104 are formed on theinterconnect structure 122 a. The contact pads 104 may be of the samesize or of different sizes. The contact pad 104 shown in FIG. 1A is alsoreferred to herein as a first contact pad 104.

A via layer 106 is disposed in dielectric layer 101 a proximate theconductive layer 102. The via layer 106 may include a plurality ofconductive vias (not shown) formed therein, for example. The via layer106 is an adjacent layer to the conductive layer 102 within theinterconnect structure 122 a in some embodiments. The via layer 106 alsoincludes metallization 108 for a contact pad 115 in the first connectorcoupling region 100. The vias and metallization 108 in the via layer 106may be formed using a damascene process, by patterning the dielectriclayer 101 a and filling the patterns with conductive material.

The interconnect structure 122 a may include one or more additionalconductive layers including conductive lines and via layers includingconductive vias formed in dielectric layers beneath dielectric layer 101a, not shown in FIG. 1 (see FIG. 10).

Referring again to FIG. 1, an underball metallization (UBM) layer 110 isdisposed in the plurality of dielectric layers 101 a and 101 b proximatethe via layer 106. The UBM layer 110 is disposed in an adjacent layer tothe via layer 106 within the interconnect structure 122 a in someembodiments. The UBM layer 110 is disposed in dielectric layer 101 b inFIG. 1, for example. The UBM layer 110 includes metallization 112 thatis formed simultaneously with vias and metallization 108 in the vialayer 106 in some embodiments. A conductive material such as copper,copper alloys, or other conductive materials may be formed over thepatterned top-most dielectric material of the plurality of dielectriclayers 101 a, and the conductive material is patterned with a desiredpattern for the metallization 112 in the UBM layer 110, also leaving themetallization 108 in the via layer 106, for example. The metallization108/112 comprises a contact pad 115 in some embodiments. The contact pad115 is also referred to herein as a ground-up UBM pad 115.

The interconnect structure 122 a may comprise a redistribution layer(RDL) that provides electrical connections in a horizontal direction fora package or a packaged semiconductor device in some embodiments, forexample. The interconnect structure 122 a may also comprise other typesof interconnect structures, such as a post passivation interconnect(PPI) structure, as an example.

A connector such as the first connector 114 shown in FIG. 1 iscoupleable to the interconnect structure 122 a. The first connector 114is coupled to the contact pad 115 of the interconnect structure 122 a inFIG. 1, for example. The first connector 114 comprises a eutecticmaterial such as solder that is adapted to melt at a predeterminedtemperature, for example. The first connector 114 may comprise solderballs or solder bumps in some embodiments, as examples. The firstconnector 114 may also comprise other types of connection devices, suchas conductive bumps, conductive balls, conductive pillars, non-sphericalconnectors, or other connectors. The first connector 114 may be coupledto the contact pad 115 using a ball drop process, solder bath, or otherprocess. The first connector 114 comprises a diameter or width of about150 μm to about 300 μm, or about 180 μm to about 250 μm, as examples.The first connector 114 may also comprise other materials, types ofconnectors, formation methods, and dimensions.

The material of the upper dielectric layer 101 b is then applied to apredetermined height along the sides of the first connector 114. Theupper dielectric layer 101 b may also be formed before the firstconnector 114 is coupled to the interconnect structure 122 a. An openingis formed in the dielectric layer 101 b above the contact pad 115 afterthe dielectric layer 101 b is applied, using lithography, a laser, orother methods. The connector 114 is attached to the contact pad 115through the opening in the dielectric layer 101 b.

The first connector coupling region 100 comprises a ground-up connectorcoupling region in some embodiments. The contact pad 115 of the firstconnector coupling region 110 comprises metallization 112 in the UBMlayer 110 and metallization 108 in the via layer 106 that provide aregion for coupling a first connector 114 to the interconnect structure122 a. The first connector coupling region 110 and the contact pad 115are referred to herein as “ground-up” because the metallization 108 inthe via layer 106 of the contact pad 115 is disposed directly over acontact pad 104 in the conductive layer 102, for example. Thus, thefirst connector 114 is formed directly over the contact pad 104. Thefirst connector coupling region 100 is also referred to herein as aground-up connector coupling region, and the ground-up connectorcoupling region 100 includes a contact pad 115 comprising a ground-upUBM pad 115.

FIG. 1B is a top view of the first connector coupling region 100 shownin FIG. 1A. The first connector 114 disposed directly over the contactpad 115 is illustrated. The first connector 114 and the contact pad 115comprise a shape of a circle in FIG. 1B: the first connector 114 and thecontact pad 115 may also comprise other shapes. Dielectric layer 101 bis not shown in FIG. 1B.

FIG. 2A is a cross-sectional view that illustrates a second connectorcoupling region 125 of an interconnect structure 122 a in accordancewith some embodiments. Portions of the second connector coupling region125 are formed in the same material layers as described for the firstconnector coupling region 100, such as in dielectric layers 101 a/101 b,conductive layer 102, via layer 106, and UBM layer 110. However, thesecond connector coupling region 125 comprises a different structurethan the first connector coupling region 100. The second connectorcoupling region 125 comprises a non-ground-up connector coupling regionin some embodiments. For example, a second connector 124 coupled to theinterconnect structure 122 a is not coupled directly over a contact pad104 in the conductive layer 102. Rather, the second connector 124 isdisposed over and is coupled to a PPI pad 118 formed in the UBM layer110. The second connector 124 comprises similar materials, types ofconnectors, formation methods, and dimensions as described for the firstconnector 114 shown in FIGS. 1A and 1B.

The PPI pad 118 in the second connector coupling region 125 is coupledto a second contact pad 104′ in the conductive layer 102 by a conductivesegment comprised of a PPI line 120 and a transition element 121 in theUBM layer 110 and a via region 116 in the via layer 106. The secondconnector coupling region 125 is also referred to herein as anon-ground-up connector coupling region, and the non-ground-up connectorcoupling region 125 includes the PPI pad 118.

FIG. 2B is a top view of the second connector coupling region 125 shownin FIG. 2A. The transition element 121 disposed between the PPI pad 118and the PPI line 120 may comprise a substantially triangular shape inthe top view. The transition element 121 may also comprise other shapes.The conductive segment that includes the PPI line 120 also includes avia region 116 that extends into the via layer 106 and makes electricalcontact with the contact pad 104′. The PPI line 120 may comprise asubstantially straight line, or the PPI line 120 may comprise ameandering line, as shown in phantom (e.g., in dashed lines) in FIG. 2B.The second connector 124 and the PPI pad 118 comprise a shape of acircle in FIG. 2B: the second connector 124 and the PPI pad 118 may alsocomprise other shapes. Dielectric layer 101 b is not shown in FIG. 2B.

The first connectors 114 and the second connectors 124 comprise the samematerials and are formed simultaneously on an interconnect structure 122a. The first connectors 114 and the second connectors 124 have differentelement numbers in the present disclosure because the first connectors114 and the second connectors 124 are coupled to different types ofconnector coupling regions and contact pads (i.e., the first connectorcoupling regions 100 and ground-up UBM pads 115, and the secondconnector coupling regions 125 and PPI pads 118, respectively).

FIG. 3 is a bottom view that shows a plurality of connectors 114 and 124of an interconnect structure 122 a in accordance with some embodiments.The first and second connectors 114 and 124 are coupled to firstconnector coupling regions 100 and second connector coupling regions125, respectively, as illustrated in FIGS. 1A, 1B, 2A, and 2B. Eachfirst connector 114 is coupled to a ground-up UBM pad 115 (not shown inFIG. 3; see FIGS. 1A and 1B) in the first connector coupling regions100, and each second connector 125 is coupled to a PPI pad 118 (also notshown in FIG. 3; see FIGS. 2A and 2B) in the second connector couplingregions 125. The connectors 114 and 124 are arranged in an array 126 ofrows and columns. The array 126 is fully populated in the embodimentsshown in FIG. 3: the array 126 may also be partially populated withvarious patterns in other embodiments. The array 126 may be formed as agrid, referred to as a “ball grid array” or “BGA”. The array 126 mayalso be arranged in other shapes.

The first connector coupling regions 100 and first connectors 114 aredisposed in corners 128 of the array 126 in the embodiments shown inFIG. 3. The first connector coupling regions 100 and first connectors114 may also be disposed in other areas of the array 126, which will bedescribed further herein with respect to FIGS. 5, 6, 7, and 9. Thesecond connector coupling regions 125 and second connectors 124 areformed in other areas or regions of the array 126 than the corners 128.For example, the second connector coupling regions 125 and secondconnectors 124 are formed in non-corners of the array 126 in theembodiments shown.

In some embodiments, the first connector coupling regions 100 thatcomprise the ground-up connector coupling regions are placed in areas ofthe array 126 that are determined to have relatively high stress levelsand/or reliability risk issues. For example, stress levels of a package(e.g., of the interconnect structure 122 a of a packaged semiconductordevice) may be analyzed to determine which locations in the array 126 toplace the first connector coupling regions 100 in. Likewise, reliabilityrisk of a package or interconnect structure 122 a may be analyzed todetermine which locations in the array 126 to place the first connectorcoupling regions 100.

In some embodiments, an analysis of a distance from a neutral positionor point NP to connector locations of the array 126 may be made todetermine if a higher likelihood of cracking or breaking of connections,higher thermal or mechanical stress, and/or higher reliability risks ofthe connector locations exists, in order to determine which regions ofthe array 126 of connector locations would benefit from placement of thefirst connector coupling regions 100 that comprise the ground-upconnector coupling regions. For example, a desired value of a distanceto the neutral point (see DNP2 in FIG. 3) for connector locations in thearray 126 may be determined, and a measurement or estimate of the actualdistances to the neutral point NP to each of the connector locations maybe made. The neutral position NP may comprise a center of the array 126of connectors 114 and 124 in some embodiments. The NP may also belocated elsewhere in the array 126. Connector locations having adistance to the neutral point measurement or estimate (DNP1 in FIG. 3)that is greater than the predetermined desired value of the distance tothe neutral point DNP2, such as the corners 128 of the array 126 in FIG.3, may be designed to include first connector coupling regions 100 thatcomprise the ground-up connector coupling regions, for example. In areasof the array 126 other than the corners 128, the second connectorcoupling regions 125 and second connectors 124 are formed. Theselocations for the second connector coupling regions 125 and secondconnectors 124 in a central region and edge regions of the array 126have a DNP measurement or estimate that is less than or equal to DNP2,for example.

The ground-up UBM pads 115 are robust and are adapted to withstand highthermal and mechanical stress, being coupled directly over contact pads104 in the underlying conductive layer 102. Thus, by placing theground-up connector coupling regions 100 comprising the ground-up UBMpads 115 in areas of the array 126 that are determined to haverelatively high stress levels and/or reliability risk issues,reliability and yields of the interconnect structure 122 a and packageare advantageously improved.

In some embodiments, the interconnect structure 122 a comprises aportion of a packaging device. The first connector coupling regions 100are located in a first region of the packaging device comprising a firstamount of stress (i.e., in a corner 128), and the second connectorcoupling regions 125 are located in a second region of the packagingdevice comprising a second amount of stress (i.e., an area of thepackaging device not in a corner), wherein the first amount of stress isgreater than the second amount of stress, for example. In someembodiments, the first connector coupling regions 100 comprise a firstDNP, such as DNP1, and the second connector coupling regions comprise asecond DNP, such as DNP2, wherein the first DNP is greater than thesecond DNP, as another example.

FIG. 4 is a cross-sectional view that illustrates a POP device 160 inaccordance with some embodiments that includes a plurality of the firstand second connectors 114 and 124 coupled to the plurality of firstconnector coupling regions 100 and the plurality of second connectorcoupling regions 125, respectively. The POP device 160 includes a secondpackaged semiconductor device 140 coupled to a first packagedsemiconductor device 130 by a plurality of third connectors 141. Thethird connectors 141 comprise similar materials, connector types,dimensions, and formation methods as described for the first connectors114. The POP device 160 may be coupled to a substrate 152 to form achip-on-wafer-on-substrate (CoWoS) device 170 in some embodiments, whichis also shown in FIG. 4.

The first packaged semiconductor device 130 includes a firstinterconnect structure 122 a that includes the second connector couplingregions 125 that include the PPI pads 118 (not labelled in FIG. 4; seeFIG. 2A) in central regions and regions other than the corners 128 ofthe array 126, and first connector coupling regions 100 that include theground-up UBM pads 115 (not labelled in FIG. 4; see FIG. 1A) in thecorners 128 of the array 126. The first packaged semiconductor device130 comprises one or more integrated circuit dies 132 (two integratedcircuit dies 132 are shown in FIG. 4) coupled to the first interconnectstructure 122 a, and a molding material 138 disposed around theintegrated circuit dies 132 and over the first interconnect structure122 a. A plurality of through-vias 136 is disposed within the moldingmaterial 138 and is coupled to the first interconnect structure 122 a.

The first packaged semiconductor device 130 includes a secondinterconnect structure 122 c that is coupled to the integrated circuitdies 132, the molding material 138, and the plurality of through-vias136. The second interconnect structure 122 c comprises an RDL, PPIstructure, or other type of interconnect structure that is formed overthe molding material 138, the plurality of through-vias 136, and theintegrated circuit dies 132. The second interconnect structure 122 ccomprises similar material layers, materials, and features as describedfor the first interconnect structure 122 a, for example, such asdielectric layers 101 a/101 b, conductive layers 102, via layers 106,and UBM layers 110 (not labelled in the second interconnect structure122 c). The second interconnect structure 122 c may also comprise thesame or different material layers, materials, and features as describedfor the first interconnect structure 122 a. The second interconnectstructure 122 c provides electrical connections in a horizontaldirection for the first packaged semiconductor device 130 in someembodiments, for example. The first interconnect structure 122 acomprises front-side routing, and the second interconnect structure 122c comprises back-side routing (i.e., relative to the integrated circuitdies 132) for the packaged semiconductor devices 130 in someembodiments.

The first interconnect structure 122 a is coupled to a first side (e.g.,the bottom side in FIG. 4) of the integrated circuit dies 132, themolding material 138, and the plurality of through-vias 136, and thesecond interconnect structure 122 c is coupled to a second side (e.g.,the top side in FIG. 4) of the integrated circuit dies 132, the moldingmaterial 138, and the plurality of through-vias 136. The second side ofthe integrated circuit dies 132, the molding material 138, and theplurality of through-vias 136 is opposite the first side.

In some embodiments, to package the semiconductor devices comprising theintegrated circuit dies 132, the first interconnect structure 122 a maybe formed first, and the through-vias 136, integrated circuit dies 132,and the molding material 138 are formed over the first interconnectstructure 122 a. Then, the second interconnect structure 122 c isformed. In other embodiments, the second interconnect structure 122 cmay be formed first, and the through-vias 136, integrated circuit dies132, and the molding material 138 are formed over the secondinterconnect structure 122 c. Then, the first interconnect structure 122a is formed.

One or more carriers (not shown) may be used to package the integratedcircuit dies 132 in the first packaged semiconductor device 130, forexample. The first interconnect structure 122 a, the second interconnectstructure 122 c, or both, may be formed on a carrier, for example, andthen the other material layers and elements are formed or attached. Thecarrier may comprise a wafer or other type of substrate that is used forthe packaging process as a platform for packaging the plurality ofintegrated circuit dies 132. The carrier(s) may also comprise a carriertape. The carrier(s) are removed after the packaging process for thefirst packaged semiconductor device 130 is completed. A plurality offirst packaged semiconductor devices 130 may be formed over a carrierand processed. Dozens, hundreds, or more first packaged semiconductordevices 130 may be formed over a carrier in an array of rows andcolumns, for example. The plurality of first packaged semiconductordevices 130 are singulated, before or after coupling a second packagedsemiconductor device 140 to each of the first packaged semiconductordevices 130, for example. In other embodiments, the first packagedsemiconductor devices 130 are not coupled to another packaged device,and the first packaged semiconductor devices 130 are used in an endapplication by coupling them in the end application using the first andsecond connectors 114 and 124.

Although two integrated circuit dies 132 are shown in FIG. 4, a singleintegrated circuit die 132 or three or more integrated circuit dies 132may be included in a first packaged semiconductor device 130, forexample. Each of the plurality of integrated circuit dies 132 includesan interconnect structure 122 b formed thereon and contacts 134 disposedon a bottom surface thereof which are formed in an insulating material.In some embodiments, the contacts 134 comprise copper vias and theinsulating material comprises PBO, as examples. The contacts 134 andinsulating material may also comprise other materials. The plurality ofintegrated circuit dies 132 may comprise logic devices, processors, orother devices, as example. The integrated circuit dies 134 initially arein wafer form and are separated using a saw along scribe lines. Theplurality of integrated circuit dies 132 may be placed on the firstinterconnect structure 122 a (or on the second interconnect structure122 c) using a pick-and-place machine or manually, for example. Thecontacts 134 are electrically connected to portions of the firstinterconnect structure 122 a such as to contact pads or vias of thefirst interconnect structure 122 a, e.g., using a eutectic material suchas solder in embodiments wherein the first interconnect structure 122 ais first formed, or using a die attach film (DAF) 133, in embodimentswherein the second interconnect structure 122 c is first formed, asexamples. The integrated circuit die or dies 132 may also be attached orcoupled to the first and second interconnect structures 122 a and 122 cusing other methods.

The plurality of through-vias 136 may be formed over the firstinterconnect structure 122 a or over the second interconnect structure122 c by plating, photolithography, or other methods, before or afterthe integrated circuit dies 132 are coupled to the first interconnectstructure 104 a or over the second interconnect structure 122 c. In someembodiments, first, the plurality of through-vias 136 is plated over thefirst interconnect structure 122 a or over the second interconnectstructure 122 c, and second, the integrated circuit dies 132 areattached to the first interconnect structure 122 a or to the secondinterconnect structure 122 c, for example. The plurality of through-vias136 may be formed using an electro-plating process, by depositing aninsulating material (not shown) over the interconnect structure 122 a or122 c, and patterning the insulating material with a desired pattern forthe through-vias 136. The through-vias 136 are plated onto theinterconnect structure 122 a or 122 c through the patterned insulatingmaterial, and the insulating material is then removed. A seed layer maybe formed before the plating process, for example. The through-vias 136may comprise copper, a copper alloy, other metals, or other materials.Dozens or hundreds of through-vias 136 may be included in a package foreach of the integrated circuit dies 132 or groups of integrated circuitdies 132 that are packaged together, for example. The plurality ofthrough-vias 136 provides electrical connections in a vertical directionfor the packaged semiconductor devices in some embodiments. Each of theplurality of through-vias 136 may be coupled to a conductive via,contact pad, or conductive line of the first interconnect structure 122a or the second interconnect structure 122 c, for example.

The molding material 138 is disposed between the through-vias 136 andintegrated circuit dies 132 and between adjacent ones of the pluralityof through-vias 136 and integrated circuit dies 132. The moldingmaterial 138 comprises a molding compound comprised of an insulatingmaterial, such as an epoxy, a filler material, a stress release agent(SRA), an adhesion promoter, other materials, or combinations thereof,as examples. The molding material 138 comprises a liquid or gel whenapplied so that it flows between and around the plurality ofthrough-vias 136 and integrated circuit dies 132, in some embodiments.The molding material 138 is then cured or allowed to dry so that itforms a solid. As deposited, the molding material 138 may extend overtop surfaces of the integrated circuit dies 132 and the plurality ofthrough-vias 136. In accordance with some embodiments, after the moldingmaterial 138 is applied, a top portion of the molding material 138 isremoved using a planarization process, such as a CMP process, a grindingprocess, an etch process, or combinations thereof, as examples. Othermethods may also be used to planarize the molding material 138. A topportion of the integrated circuit dies 132 and/or through-vias 136 mayalso be removed during the planarization process for the moldingmaterial 138.

After the planarization process for the molding material 138, the secondinterconnect structure 122 c (or the first interconnect structure 122 a,in embodiments wherein the second interconnect structure 122 c is firstformed) is then formed over the molding material 138, through-vias 136,and the integrated circuit dies 132.

The first packaged semiconductor devices 130 comprise fan-out structuresin some embodiments. For example, the conductive wiring is spaced outfarther in the first and second interconnect structures 122 a and 122 cthan conductive wiring is spaced in the interconnect structure 122 b ofthe integrated circuit dies 132. Likewise, the footprint of contact padsin or on the first and second interconnect structures 122 a and 122 c islarger than the footprint of the contacts 134 of the integrated circuitdies 132.

A first connector 114 is coupled to each of the first connector couplingregions 100 in the corners 128 of the interconnect structure 122 a andfirst packaged semiconductor device 130. Likewise, a second connector124 is coupled to each of the second connector coupling regions 125 inregions of the array 126 other than the corners 128. The connectors 114and 124 may be coupled to the first interconnect structure 122 a atvarious points in the packaging process, such as after the packagingprocess, before the formation of the molding material 138, attachment ofthe integrated circuit dies 132 and/or through-vias 136, or formation ofthe second interconnect structure 122 c, as examples.

The packaging process flow for packaging integrated circuit dies 102 aand forming packaged semiconductor devices 130 may also comprise otherprocessing steps and orders of the processing steps.

In some embodiments, after the packaging process is complete for thefirst packaged semiconductor device 130, a plurality of the packagedsemiconductor devices 130 is singulated along scribe lines to form aplurality of separated first packaged semiconductor devices 130. Thepackaged semiconductor devices 130 may be singulated using a saw, whichmay include a blade comprising diamond or other materials in someembodiments, for example. In other embodiments, the first packagedsemiconductor devices 130 are singulated after second packagedsemiconductor devices 140 are attached.

In some embodiments wherein the second packaged semiconductor devices140 are coupled to the first packaged semiconductor devices 130 usingconnectors 141 to form a POP device 160 shown in FIG. 4, before thepackaged semiconductor devices 130 are singulated, a plurality of thesecond packaged semiconductor devices 140 is provided, and each of theplurality of second packaged semiconductor devices 140 is coupled to oneof the first packaged semiconductor devices 130 using the plurality ofthird connectors 141 coupled to the second interconnect structure 122 cof the first packaged semiconductor devices 130, coupled to the secondpackaged semiconductor devices 140, or coupled to both the firstpackaged semiconductor devices 130 and the second packaged semiconductordevices 140. The plurality of second packaged semiconductor devices 140may include integrated circuit dies 142 that have been encapsulated withprotective materials, and electrical wiring structures may be coupled tothe integrated circuit dies 142, to be described further herein. Thesecond packaged semiconductor devices 140 are coupled to theunsingulated first packaged semiconductor devices 130 by a method suchas manually by an operator or technician, the use of an automatedmachine such as a pick-and-place machine, or other methods. Theplurality of first packaged semiconductor devices 130 is then singulatedto form the POP devices 160.

Each of the plurality of second packaged semiconductor devices 140 maycomprise a substrate 144 that includes a plurality of contact pads 146 aand 146 b disposed on. The substrate 144 may include one or moreinterconnect structures (not shown) formed thereon that providehorizontal connections for the plurality of second packagedsemiconductor devices 140 in some embodiments. The substrate 144 mayalso include a plurality of through-vias (also not shown) formedtherein. One or more integrated circuit dies 142 may be coupled to a topsurface of the substrate 144. Each of the plurality of second packagedsemiconductor devices 140 comprises two vertically stacked integratedcircuit dies 142 in the embodiments shown in FIG. 4, for example. Two ormore integrated circuit dies 142 may also be packaged togetherhorizontally in the second packaged semiconductor devices 140 in someembodiments, not shown.

In the embodiments shown, the integrated circuit dies 142 are coupled tocontact pads 146 a disposed on a top surface of the substrate 144 bybond wires 148. The bond wires 148 and through-vias in the substrate 144provide vertical electrical connections for the plurality of secondpackaged semiconductor devices 140 in some embodiments. A moldingmaterial 150 is disposed over the integrated circuit dies 142, the bondwires 148, and the substrate 144. The molding material 150 may comprisesimilar materials as described for the molding material 138 of the firstsemiconductor device 130, for example. The molding material 138 of thefirst packaged semiconductor device 130 is also referred to herein as afirst molding material 138, and the molding material 150 of the secondpackaged semiconductor device 140 is also referred to herein as a secondmolding material 150.

In some embodiments, the integrated circuit die or dies 142 compriseDRAM devices, for example. The integrated circuit dies 142 may alsocomprise other types of devices. One or more integrated circuit dies 142may be included in the second packaged semiconductor devices 140. Theintegrated circuit dies 142 may be packaged together vertically asshown, or horizontally. The integrated circuit dies 142 may be packagedin a wire bond type of package as shown in FIG. 4, or the integratedcircuit dies 142 may be packaged in other types of packages and usingother types of packaging techniques.

After the second packaged semiconductor devices 140 are coupled to thefirst packaged semiconductor devices 130 using the plurality of thirdconnectors 141, as shown in FIG. 4, a eutectic material of theconnectors 141 is then reflowed and is allowed to cool, whichmechanically and electrically couples the second packaged semiconductordevice 140 to the first packaged semiconductor device 130. Each of theplurality of second packaged semiconductor devices 140 is coupled to oneof the plurality of first packaged semiconductor devices 130 using someof the plurality of connectors 141, for example. The plurality of firstpackaged semiconductor devices 130 and the plurality of second packagedsemiconductor devices 140 are arranged in an array of rows and columnsin some embodiments. The POP devices 160 are then singulated along thescribe lines. The POP devices 160 may then be coupled to another deviceor object using the plurality of first and second connectors 114 and 124disposed on the bottom surfaces of the POP device 160, e.g., using asurface mount technology (SMT) process.

FIGS. 5, 6, and 7 are bottom views that show a plurality of connectorsof an interconnect structure in accordance with some embodiments. Someembodiments are shown wherein the first connector coupling regions 100that include the ground-up UBM pads 115 and first connectors 114 coupledto the ground-up UBM pads 115 are disposed in various regions of thearray 126. In FIG. 5, the first connector coupling regions 100 thatinclude the ground-up UBM pads 115 and first connectors 114 are disposedin corner regions 162 of the array 126. The other areas of the array 126such as the central region and portions of the edge region that do notinclude the corner regions 162 include second connector coupling regions125 that include the PPI pads 118 and second connectors 124 coupled tothe PPI pads 118 disposed therein. The second connector coupling regions125 are disposed in regions of the array 126 other than the cornerregions 162, for example.

Each corner region 162 of the array 126 shown in FIG. 5 includes threefirst connector coupling regions 100 and three first connectors 114, forexample. The corner regions 162 of the array 126 may also comprise othernumbers of first connector coupling regions 100 and first connectors114. The predetermined desired value of the distance to the neutralpoint DNP2 is less than the predetermined desired value of the distanceto the neutral point DNP2 shown in FIG. 3, or the array 126 in FIG. 5 islarger than the array 126 in FIG. 3, as examples.

In FIG. 6, some embodiments of the present disclosure are shown whereinthe predetermined desired value of the distance to the neutral pointDNP2 is less than the predetermined desired value of the distance to theneutral point DNP2 shown in FIG. 5, or the array 126 in FIG. 6 is largerthan the array 126 in FIG. 5. Thus, additional first connector couplingregions 100 are included in the array 126. The first connector couplingregions 100 that include the ground-up UBM pads 115 and first connectors114 are disposed in corner regions and edge regions 164 of the array126. Second connector coupling regions 125 that include the PPI pads 118and second connectors 124 coupled to the PPI pads 118 are disposed inthe other areas of the array 126, such as the central region of thearray 126.

FIG. 7 illustrates some embodiments wherein the first connector couplingregions 100 are included in the array 126 proximate some of the corners166 of the integrated circuit dies 132 coupled to the interconnectstructure 122 a. In some embodiments, the first connector couplingregions 100 that include the ground-up UBM pads 115 and first connectors114 may be included in the array 126 only proximate some of the corners166 of the integrated circuit die 132, not shown in the drawings. Inother embodiments, as shown in FIG. 7, the first connector couplingregions 100 that include the ground-up UBM pads 115 and first connectors114 are also disposed in the corners 128 of the array 126, in additionto proximate the corners 166 of the integrated circuit dies 132. In yetother embodiments, not shown, the first connector coupling regions 100may also be disposed in the corner regions 162 of the array 126, asshown in FIG. 5, in addition to proximate the corners 166 of theintegrated circuit dies 132. In other embodiments, also not shown, thefirst connector coupling regions 100 may also be disposed in the cornerregions and edge regions 164 of the array 126, as shown in FIG. 6, inaddition to proximate the corners 166 of the integrated circuit dies132, as another example. Second connector coupling regions 125 thatinclude the PPI pads 118 and second connectors 124 coupled to the PPIpads 118 are disposed in the other areas of the array 126 other thanwhere the first connector coupling regions 100 are disposed or located.

In embodiments wherein two or more integrated circuit dies 132 arepackaged together in a single package, the inner corner regions 127 maycomprise lower stress and lower reliability risk, and first connectorcoupling regions 100 may not be required to be implemented in theselocations. Rather, second connector coupling regions 125 may be used inthe inner corner regions 127. The first connector coupling regions 100may also be implemented in the inner corner regions 127, in otherembodiments.

In some embodiments, the first connector coupling regions 100 areincluded in the array 126 for connector regions directly beneath theouter corners of the integrated circuit dies 132, as shown in FIG. 7. Inother embodiments, the first connector coupling regions 100 are includedin the array for connector regions near the outer corners of theintegrated circuit dies 132. For example, connector region 129 comprisesa connector region that is a first connector region outside the locationof the integrated circuit die 132 corner. A first connector couplingregion 100 is placed in this location, in some embodiments. The firstconnector coupling regions 100 may also be placed in other locationsproximate the corners of the integrated circuit dies 132.

FIG. 8 is a cross-sectional view that illustrates a POP device 160 and aCoWoS device 170 in accordance with some embodiments. Note that all ofthe elements of the first packaged semiconductor device 130 and thesecond semiconductor device 140 are not labeled in FIG. 8, in order tosimplify the drawing: FIG. 4 may be referred to again for more detailedelement numbers and descriptions thereof.

FIG. 8 illustrates the embodiments shown in FIG. 7 implemented in afirst packaged semiconductor device 130. Corners 128 of the array 126,first interconnect structure 122 a, and first packaged semiconductordevice 130 include the first connector coupling regions 100 that includethe ground-up UBM pads 115 and first connectors 114 that are coupled tothe ground-up UBM pads 115. The first connector coupling regions 100 arealso included in the array 126 proximate corners 166 of the integratedcircuit dies 132. Second connector coupling regions 125 that include thePPI pads 118 and second connectors 124 coupled to the PPI pads 118 aredisposed in the other areas of the array 126 where the first connectorcoupling regions 125 are disposed or located.

FIG. 9 is a bottom view that shows a plurality of connectors 114 and 124of a first interconnect structure 122 a in accordance with someembodiments. The first connector coupling regions 100 are included inthe array 126 proximate corner regions 168 of the integrated circuitdies 132. Each corner region 168 of the integrated circuit dies 132shown in FIG. 9 includes four first connector coupling regions 100 andfour first connectors 114, for example. The corner regions 168 of theintegrated circuit dies 132 may also comprise other numbers of firstconnector coupling regions 100 and first connectors 114. The two cornerrows of connector locations closest to the outer corners of theintegrated circuit dies 132 may include the first connector couplingregions 100 in some embodiments, for example.

In some embodiments, the first connector coupling regions 100 thatinclude the ground-up UBM pads 115 and first connectors 114 may beincluded in the array 126 only proximate the corner regions 168 of theintegrated circuit die 132, not shown in the drawings. In otherembodiments, as shown in FIG. 9, the first connector coupling regions100 that include the ground-up UBM pads 115 and first connectors 114 arealso disposed in the corners 128, in addition to proximate the cornerregions 168 of the integrated circuit dies 132. In yet otherembodiments, not shown, the first connector coupling regions 100 mayalso be disposed in the corner regions 162 of the array 126, as shown inFIG. 5, in addition to proximate the corner regions 168 of theintegrated circuit dies 132. In other embodiments, also not shown, thefirst connector coupling regions 100 may also be disposed in the cornerregions and edge regions 164 shown in FIG. 6, in addition to proximatethe corner regions 168 of the integrated circuit dies 132, as anotherexample. Second connector coupling regions 125 that include the PPI pads118 and second connectors 124 coupled to the PPI pads 118 are disposedin the other areas of the array 126 than where the first connectorcoupling regions 100 are disposed or located.

Note that the descriptions of the bottom views of the first interconnectstructures 122 a comprising an array 126 shown in FIGS. 3, 5, 6, 7, and9 of the various areas where the first connector coupling regions 100are located in the array 126 may also be used to described where thefirst connector coupling regions 100 are located in the interconnectstructure 122 a, the first packaged semiconductor device 130, a POPdevice 160, or a CoWoS device 170, because the array 126 comprises acomponent of the interconnect structure 122 a, the first packagedsemiconductor device 130, the POP device 160, and/or the CoWoS device170, for example.

FIG. 10 is a cross-sectional view of a portion of a first packagedsemiconductor device 130 that illustrates additional material layers ofa first interconnect structure 122 a in accordance with someembodiments. Conductive material layers 172 are disposed below theconductive layer 102 within the dielectric layers 101 a, for example.The conductive material layers 172 include a plurality of conductivelines and vias, some of which are coupled to the through-vias 136 or thecontacts 134 of the integrated circuit die 132. A passivation layer 174comprising an insulating material is disposed over the integratedcircuit die 132 and over portions of the contacts 134. An opening isformed in the passivation layer 174 so that electrical connection may bemade to the contacts 134 by conductive lines and vias in the conductivematerial layer 172. Openings 176 are formed in a passivation layer 178disposed over a back side of the integrated circuit die 132 and moldingmaterial 138, so that electrical connections may be made to thethrough-vias 136 by a subsequently formed second interconnect structure122 c (not shown in FIG. 10; see FIG. 4). FIG. 10 also illustrates thata first connector coupling region 100 may be formed adjacent a secondconnector coupling region 125 within an interconnect structure 122 a.

FIG. 11 is a flow chart 180 illustrating a method of packaging asemiconductor device in accordance with some embodiments. In step 182,an initial interconnect structure design for a semiconductor devicepackage 130 is determined. The initial interconnect structure comprisesconnector coupling regions that each comprise a PPI pad 118. In step184, an amount of reliability risk for each of the connector couplingregions is determined. For example, a measurement or estimate of theactual distances to the neutral point NP to each of the connectorlocations may be made, with the distances being indicative of an amountof reliability risk for each connector location. In step 186, athreshold amount of reliability risk is determined. As an example, adesired value of a distance to the neutral point (see DNP2 in FIGS. 3,5, and 6) for connector locations in the array 126 may be determinedbased on a reliability risk factor determined. In step 188, the initialinterconnect structure design is re-designed or altered, by replacingthe PPI pads 118 in connector regions having an amount of reliabilityrisk greater than the threshold amount (see DNP1 in FIGS. 3, 5, and 6)with ground-up UBM pads 115. In step 189, an integrated circuit die 132is then packaged with an interconnect structure 122 a comprising thealtered interconnect structure design.

Embodiments of the present disclosure are advantageously implementablein and are particularly beneficial when used in POP devices, in someapplications. The packaged semiconductor devices may comprise POPdevices, system-on-a chip (SOC) devices, CoWoS devices, or other typesof 3DICs in some embodiments, as examples.

In some embodiments, the first integrated circuit dies 132 compriselogic devices or processors and the first packaged semiconductor devices130 comprise fan-out wiring, and the second integrated circuit dies 142comprise memory devices such as DRAM devices, e.g., in some embodimentswherein the ground-up UBM pad and PPI pad placement described herein isimplemented in an integration fan-out (InFO) POP device 160. In someembodiments, the second packaged semiconductor devices 140 include aplurality of stacked integrated circuit dies 142 comprising DRAMdevices, for example. The first integrated circuit dies 132, the secondintegrated circuit dies 142, the first packaged semiconductor devices130, and the second packaged semiconductor devices 140 may also compriseother types of devices, and the ground-up UBM pad 115 and PPI pad 118placement and processes described herein may be implemented in othertypes of applications.

Some embodiments of the present disclosure include interconnectstructures 122 a, packaged semiconductor devices 130, POP devices 160,and CoWoS devices 170 that include the first connector coupling regions100 that include ground-up UBM pads 115 in corners or corner regions ofthe interconnect structures 122 a or package, while other areas includesecond connector coupling regions 125 that include PPI pads 118. Otherembodiments include methods of packaging semiconductor devices usinginterconnect structures 122 a that include first connector couplingregions 100 that include the ground-up UBM pads 115 in corners or cornerregions of the interconnect structures 122 a or packages, and secondconnector coupling regions 125 that include PPI pads 118 in other areas.

Advantages of some embodiments of the present disclosure includeproviding packaging methods for POP devices, CoWoS devices, and othertypes of 3DICs that have robust ground-up UBM pads in high reliabilityrisk and stress locations, such as corners and corner regions of thepackage and/or proximate the corners or corner regions of integratedcircuit dies in the package. Reliability and yields of the packageddevices are improved. Cracks in the interconnect structure anddelamination of dielectric layers are reduced or eliminated byimplementing the ground-up UBM pads in high reliability risk and stresslocations. Damage to the packaged semiconductor devices from high stresslevels that may be caused by thermal cycling during testing,transportation, or in an end application are also reduced or eliminated.Furthermore, the packaging methods and structures described herein areeasily implementable into existing packaging process flows andstructures.

The first connector coupling regions and first connectors describedherein may be located in a corner of a packaged semiconductor device, acorner region of a packaged semiconductor device, an edge region of apackaged semiconductor device, proximate a corner or a corner region ofan integrated circuit die within the packaged semiconductor device, orother locations. The second connector coupling regions are located inregions other than where the first connector coupling regions arelocated. For example, the second connector coupling regions and thesecond connectors described herein may be located in a region otherthan: a corner of a packaged semiconductor device, a corner region of apackaged semiconductor device, an edge region of a packagedsemiconductor device, or proximate a corner or a corner region of anintegrated circuit die within the package.

In some embodiments of the present disclosure, an interconnect structureincludes a plurality of dielectric layers, a conductive layer disposedin the plurality of dielectric layers, and a via layer disposed in theplurality of dielectric layers proximate the conductive layer. Theinterconnect structure includes a UBM layer disposed in the plurality ofdielectric layers proximate the via layer. A first connector couplingregion is disposed in the via layer and the UBM layer, a via layerportion of the first connector coupling region being coupled to a firstcontact pad in the conductive layer. A second connector coupling regionis disposed in the UBM layer, the second connector coupling region beingcoupled to a conductive segment in the UBM layer and the via layer. Thesecond connector coupling region is coupled to a second contact pad inthe conductive layer by the conductive segment.

In other embodiments, a packaged semiconductor device includes a moldingmaterial, an integrated circuit die disposed within the moldingmaterial, and a plurality of through-vias disposed within the moldingmaterial. An interconnect structure is coupled to the integrated circuitdie, the molding material, and the plurality of through-vias. Theinterconnect structure includes a plurality of dielectric layers, aconductive layer disposed in the plurality of dielectric layers, a vialayer disposed in the plurality of dielectric layers proximate theconductive layer, and a UBM layer disposed in the plurality ofdielectric layers proximate the via layer. The interconnect structureincludes a first connector coupling region disposed in the via layer andthe UBM layer, a via layer portion of the first connector couplingregion being coupled to a first contact pad in the conductive layer. Theinterconnect structure also includes a second connector coupling regiondisposed in the UBM layer, the second connector coupling region beingcoupled to a conductive segment in the UBM layer and the via layer. Thesecond connector coupling region of the interconnect structure iscoupled to a second contact pad in the conductive layer by theconductive segment. The packaged semiconductor device includes a firstconnector coupled to the first connector coupling region of theinterconnect structure, and a second connector coupled to the secondconnector coupling region of the interconnect structure.

In yet other embodiments, a method of packaging a semiconductor deviceincludes determining an initial interconnect structure design for asemiconductor device package, the initial interconnect structurecomprising a plurality of connector coupling regions, each of theplurality of connector coupling regions comprising a PPI pad. An amountof reliability risk for the plurality of connector coupling regions isdetermined, and a threshold amount of reliability risk is determined.The method includes altering the initial interconnect structure designby replacing PPI pads in the plurality of connector coupling regionshaving an amount of reliability risk greater than the threshold amountwith ground-up UBM pads. An integrated circuit die is then packaged withan interconnect structure comprising the altered interconnect structuredesign.

In yet other embodiments, a method of forming a semiconductor structureincludes forming an interconnect structure, including depositing aconductive layer having a first contact pad and a second contact pad,depositing a first dielectric layer on the conductive layer, forming aground-up underbump metallization (UBM) pad disposed on the firstdielectric layer in a first region of the interconnect structure, thefirst region of the interconnect structure determined to be under afirst amount of stress, a first portion of the ground-up UBM padextending through the first dielectric layer to contact the firstcontact pad in the conductive layer, the first portion of the ground-upUBM pad having a recessed top surface, and forming a post-passivationinterconnect (PPI) on the first dielectric layer, the PPI being a singlecontinuous conductive material in a second region of the interconnectstructure, the second region of the interconnect structure determined tobe under a second amount of stress, the second amount of stress lessthan the first amount of stress, the PPI including a PPI pad and aconductive segment, the conductive segment extending through the firstdielectric layer to contact the second contact pad in the conductivelayer, the PPI pad having a flat top surface. The method furtherincludes depositing a second dielectric layer over the UBM pad and thePPI, forming a plurality of through-vias on the interconnect structure,attaching an integrated circuit die to the interconnect structure,depositing a molding material over the interconnect structure, theplurality of through-vias, and the integrated circuit die, coupling afirst connector to the ground-up UBM pad, the first connector contactingsidewalls and the recessed top surface of the ground-up UBM pad,coupling a second connector to the PPI pad, the second connectorphysically contacting the flat top surface of the PPI pad, anddepositing a second dielectric layer on the interconnect structure. Aportion of a spherical top surface of the first connector is covered bythe second dielectric layer, and at least a portion of the lower half ofa spherical top surface of the second connector is covered by the seconddielectric layer.

In yet other embodiments, a method of forming a semiconductor deviceincludes determining an amount of reliability risk for a plurality ofconnector coupling regions, determining a threshold amount ofreliability risk, and forming an interconnect. The forming theinterconnect includes depositing a conductive layer having a pluralityof first contact pads and a plurality of second contact pads, depositinga first dielectric layer on the conductive layer, forming a plurality ofground-up underbump metallization (UBM) pads disposed on the firstdielectric layer in respective first regions of the interconnect, therespective first regions of the interconnect determined to be over thethreshold amount of reliability risk, a plurality of respective firstportions of the plurality of ground-up UBM pads extending through thefirst dielectric layer to contact respective first contact pads of theplurality of first contact pads in the conductive layer, each of therespective first portions of the plurality of ground-up UBM pads havinga respective recessed top surface, and forming a plurality ofpost-passivation interconnects (PPIs) on the first dielectric layer,each of the plurality of PPIs being a single continuous conductivematerial in respective second regions of the interconnect, therespective second regions of the interconnect determined to be under thethreshold amount of reliability risk, each of the plurality of PPIsincluding a respective PPI pad and a respective conductive segment, therespective conductive segments extending through the first dielectriclayer to contact respective second contact pads of the plurality ofsecond contact pads in the conductive layer, each respective PPI padhaving a flat top surface. The method further includes plating aplurality of through-vias on the interconnect, attaching a plurality ofdies to the interconnect, depositing a molding material over theinterconnect, the plurality of through-vias, and the plurality of dies,depositing a second dielectric layer, on the interconnect, forming aplurality of first openings and a plurality of second openings in thesecond dielectric layer, such that each of the plurality of firstopenings exposes respective ground-up UBM pads, and such that each ofthe plurality of second openings exposes respective PPI pads. The methodfurther includes coupling a plurality of first connectors to respectiveground-up UBM pads through respective first openings, each of theplurality of first connectors contacting respective sidewalls andrespective recessed top surfaces of the respective ground-up UBM pads,respective portions of respective spherical top surfaces of theplurality of first connectors being covered by the second dielectriclayer, and coupling a plurality of second connectors to respective PPIpads, each of the plurality of second connectors physically contactingrespective flat top surface of respective PPI pads through respectivesecond openings, respective portions of respective lower halves ofrespective spherical top surfaces of the plurality of second connectorsbeing covered by the second dielectric layer.

In yet other embodiments, a method of packaging a semiconductor deviceincludes forming an initial interconnect structure design for asemiconductor device package. The initial interconnect structure designincludes: a plurality of connector coupling regions, each connectorcoupling region of the plurality of connector coupling regions includinga post-passivation interconnect (PPI) pad; a plurality of firstconnectors, each first connector of the plurality of first connectorsbeing coupled to a respective PPI pad; and a dielectric layer coveringat least a first portion of a lower half of a spherical surface of afirst connector of the plurality of first connectors, at least a secondportion of the lower half of the spherical surface of the firstconnector being directly adjacent to an ambient. The method of packagingthe semiconductor device further includes: determining a first amount ofreliability risk for a first connector coupling region of the pluralityof connector coupling regions; determining a threshold amount ofreliability risk; altering the initial interconnect structure design byreplacing a PPI pad in a first connector coupling region of theplurality of connector coupling regions with a ground-up underballmetallization (UBM) pad, the first amount of reliability risk beinggreater than the threshold amount of reliability risk; and packaging anintegrated circuit die with an interconnect structure including thealtered interconnect structure design.

In yet other embodiments, a method of packaging a semiconductor deviceincludes forming an initial interconnect structure design for asemiconductor device package. The initial interconnect structure designincludes: a first dielectric layer; and a plurality of connectorcoupling regions, each connector coupling region of the plurality ofconnector coupling regions including a post-passivation interconnect(PPI) pad directly on the first dielectric layer. The method ofpackaging the semiconductor device further includes: determining a firstamount of reliability risk for a first connector coupling region of theplurality of connector coupling regions; replacing a first PPI pad in afirst connector coupling region of the plurality of connector couplingregions of the initial interconnect structure design with a ground-upunderball metallization (UBM) pad to form an altered interconnectdesign, the first amount of reliability risk being greater than athreshold amount of reliability risk, a lower surface of the ground-upUBM pad physically contacting an upper surface of the first dielectriclayer, a first portion of the ground-up UBM pad extending through thefirst dielectric layer, the first portion of the ground-up UBM padhaving a recessed top surface; and packaging an integrated circuit diewith an interconnect structure including the altered interconnectstructure design.

In yet other embodiments, a method of packaging a semiconductor deviceincludes forming an initial interconnect structure design for asemiconductor device package. The initial interconnect structure designincludes: a first dielectric layer; and a plurality of connectorcoupling regions, each connector coupling region of the plurality ofconnector coupling regions including a respective post-passivationinterconnect (PPI) directly on the first dielectric layer, eachrespective PPI including a respective PPI pad and a respectiveconductive segment, each respective lower surface of the respective PPIpad physically contacting an upper surface of the first dielectriclayer. The method of packaging the semiconductor device furtherincludes: replacing a PPI pad in a first connector coupling region ofthe plurality of connector coupling regions of the initial interconnectstructure design with a ground-up underball metallization (UBM) pad toform an altered interconnect structure design, the first connectorcoupling region having a first amount of reliability risk greater than athreshold amount of reliability risk; and packaging an integratedcircuit die with an interconnect structure including the alteredinterconnect structure design.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A method of packaging a semiconductor device, themethod comprising: forming an initial interconnect structure design fora semiconductor device package, the initial interconnect structuredesign comprising: a plurality of connector coupling regions, eachconnector coupling region of the plurality of connector coupling regionscomprising a post-passivation interconnect (PPI) pad; a plurality offirst connectors, each first connector of the plurality of firstconnectors being coupled to a respective PPI pad; and a dielectric layercovering at least a first portion of a lower half of a spherical surfaceof a first connector of the plurality of first connectors, at least asecond portion of the lower half of the spherical surface of the firstconnector being directly adjacent to an ambient; determining a firstamount of reliability risk for a first connector coupling region of theplurality of connector coupling regions; determining a threshold amountof reliability risk; altering the initial interconnect structure designby replacing a PPI pad in a first connector coupling region of theplurality of connector coupling regions with a ground-up underballmetallization (UBM) pad, the first amount of reliability risk beinggreater than the threshold amount of reliability risk; and packaging anintegrated circuit die with an interconnect structure comprising thealtered interconnect structure design.
 2. The method of claim 1, whereinpackaging the integrated circuit die comprises forming the interconnectstructure, coupling the integrated circuit die to the interconnectstructure, and forming a molding material around the integrated circuitdie.
 3. The method of claim 2, wherein packaging the integrated circuitdie further comprises coupling a plurality of through-vias to theinterconnect structure.
 4. The method of claim 3, wherein forming theinterconnect structure comprises forming a first interconnect structure,wherein packaging the integrated circuit die further comprises forming asecond interconnect structure over the molding material.
 5. The methodof claim 4, wherein the method comprises forming the first interconnectstructure, and after forming the first interconnect structure, formingthe second interconnect structure.
 6. The method of claim 4, wherein themethod comprises forming the second interconnect structure, and afterforming the second interconnect structure, forming the firstinterconnect structure.
 7. The method of claim 4, further comprisingcoupling a packaged semiconductor device to the second interconnectstructure.
 8. The method of claim 7, further comprising coupling thefirst interconnect structure to a substrate.
 9. A method of packaging asemiconductor device, the method comprising: forming an initialinterconnect structure design for a semiconductor device package, theinitial interconnect structure design comprising: a first dielectriclayer; and a plurality of connector coupling regions, each connectorcoupling region of the plurality of connector coupling regionscomprising a post-passivation interconnect (PPI) pad directly on thefirst dielectric layer; determining a first amount of reliability riskfor a first connector coupling region of the plurality of connectorcoupling regions; replacing a first PPI pad in a first connectorcoupling region of the plurality of connector coupling regions of theinitial interconnect structure design with a ground-up underballmetallization (UBM) pad to form an altered interconnect design, thefirst amount of reliability risk being greater than a threshold amountof reliability risk, a lower surface of the ground-up UBM pad physicallycontacting an upper surface of the first dielectric layer, a firstportion of the ground-up UBM pad extending through the first dielectriclayer, the first portion of the ground-up UBM pad having a recessed topsurface; and packaging an integrated circuit die with an interconnectstructure comprising the altered interconnect structure design.
 10. Themethod of claim 9, wherein the altered interconnect structure designfurther comprises forming a second dielectric layer on the firstdielectric layer.
 11. The method of claim 10, wherein the alteredinterconnect structure design further comprises coupling a firstconnector to a second PPI pad in a second connector coupling region ofthe plurality of connector coupling regions, wherein the seconddielectric layer covers a lower portion of the first connector.
 12. Themethod of claim 11, wherein an upper portion of the first connector isabove an uppermost surface of the second dielectric layer.
 13. Themethod of claim 10, wherein the altered interconnect structure designfurther comprises coupling a second connector to the ground-up UBM pad,wherein the second dielectric layer covers a lower portion of the secondconnector.
 14. The method of claim 13, wherein a sidewall of the secondconnector above the second dielectric layer is above an uppermostsurface of the second dielectric layer.
 15. A method of packaging asemiconductor device, the method comprising: forming an initialinterconnect structure design for a semiconductor device package, theinitial interconnect structure design comprising: a first dielectriclayer; and a plurality of connector coupling regions, each connectorcoupling region of the plurality of connector coupling regionscomprising a respective post-passivation interconnect (PPI) directly onthe first dielectric layer, each respective PPI comprising a respectivePPI pad and a respective conductive segment, each respective lowersurface of the respective PPI pad physically contacting an upper surfaceof the first dielectric layer; replacing a PPI pad in a first connectorcoupling region of the plurality of connector coupling regions of theinitial interconnect structure design with a ground-up underballmetallization (UBM) pad to form an altered interconnect structuredesign, the first connector coupling region having a first amount ofreliability risk greater than a threshold amount of reliability risk;and packaging an integrated circuit die with an interconnect structurecomprising the altered interconnect structure design.
 16. The method ofclaim 15, wherein the altered interconnect structure design furthercomprises a second connector coupling region, the second connectorcoupling region comprising a first PPI pad.
 17. The method of claim 16,wherein the second connector coupling region has a first distance to aneutral position (DNP) and wherein the first connector coupling regionof the altered interconnect structure design has a second DNP, thesecond DNP being greater than the first DNP.
 18. The method of claim 17,wherein the altered interconnect structure design further comprises anarray of connectors, wherein a first connector of the array ofconnectors is coupled to the ground-up UBM pad.
 19. The method of claim18, wherein the neutral position comprises a center of the array ofconnectors.
 20. The method of claim 18, wherein the first connectorcoupling region is located in a corner of the array of connectors.